Particle inlaid surface



ug. 24, 1937.I c. s. GLEZEN 2,090,836

PARTICLE INLAID SURFACE Filed July 24, 1935 3 L Mazo /SA/Vo/ ORNEY'Patented Aug. 24, 1937y 2,090,836

UNITED STATES PATENT FFICE PARTICLE INLAID SURFACE Carlisle s. Glezen,Baldwin, N. Y., assigner?v to The Safe Tread Company, Inc., New Yorky,N. Y., a. corporation o! Delaware Application* July 24, 1935, Serial No.32,840

Claims. (Cl. 22-202) This invention relates to methods for the faces, itis not limited thereto, but is understood manufacture of cast metalarticles wherein some to be applicable to analogous arts and the deofthe surfaces of the finished article are inlaid scription given isunderstood to be exemplary with particles, etc., such as abrasiveparticles, thereof.

5 etc., aixed by flowing the metal around themA This invention has forits object the provision 5 during the operation of molding. A mostcharof@ method of inlaying particles in a cast metal acteristic orcommon form .of particle inlaid cast surface whereby control of thefinal distribution metal surface is the common abrasive inlaid cast ofthe particles over the surface is more easily metal safety floor andstair read. This invenobtained. It has .for another important! obtionhas to do specically th methods for ject the provision of amethod ofinlaying wherel0 the manufacture of such objects which permit of by afirmer bonding of the inlaid particles to the economically securingcontrol over .the distribumetal may be had. It has for an object thetion of the inlay-particles in the metal surface provision of a processwhereby the surface of and of securing a iirm bond between the parsuchproducts may be freed to a great degree l5 tides and the metal, 4 i fromthe presence of slag, oxide films and the 15 In the present art offorming particle inlaid like. It has other objects and advantages whichcast metal surfaces, many methods are followed. will be in Dart ObVOuSand Part 0f Which Will 'De For instance: A mold may be prepared and thepeinted Out hereafter. inlay-particles may be sprinkled therein, the Ithas been observed that in the casting of thin pattern returned to themold and tamped to metal sections, as the metal flows over the moldforce the inlay-particles into the mold surface',`... Surface. lt ClOeSnot behave eS Would a liquid after which the pattern is removed, themold Which Wetted the mold but behaves somewhat closed and the metalpoured. 'Another method aS dOeS mercury flowing over a 4surface which isthe sprinkling of a powdered refractory mateit does not Wet, in that aSlight Skin or film of rial, such as fire clay on the face of the mold,impurities. OXideS and/0r colder metal forms on 25 followed bysprinkling the inlay-particles on the the Surface 0f the metal, and aSthe metal flOWS, nre clay, after which the mold is closed and the thiSSkin iS rolled under the advancing Wave 0f metal poured. Or theinlay-particles may be metal and depOSted between the more fluid coatedwith an adhesive composition, such as metal and the mold surfacesomewhat as a carsodium silicate, and sprinkled into the mold, Det- Duet0 this, it may be Seen that the ad- 30 and after the adhesive is driedby any of several Vancing metal iS not Capable 0f flowing freely means,the mold may be closed and the metal inte ihterStiCeS aS Would a llmpidliquid, but poured. Another process involves the coating acts sOmewhatmore in the fashion of a blunt of the mold face with adhesive andsprinkling and soft scraper and will to a great extent tend theinlay-particles thereon. Attempts have been t0 Push beOre it SmallParticles in its path, 35 made to use inlay-particles coated with veryinerather than t0 immediately Surround them. It ly divided metallicparticles to secure a bond iS my belief that this behaVOir 0f flowingmetal to the metal, and various other methods have in a mold isresponsible for many 0f the difbeen used. I have observed that in all ofthese eultleS encountered in Obtaining unifOrm 0I' methods there is sometendency for the inlaycontrolled distribution of inlaid particles, since40 particles to be displaced when metal is poured a 110W of this SortWould tend sOmeWhat to break into the mold, and in many of them it isquite the bond (however it is arrived at) by which marked. `In many ofthese processes for one the inlaid particles are held to the surface ofthe reason or another, the inlay-particles are quite meld and then wouldtend to displace them.

lmperfeetly imbedded in and/or bonded to the 0r if the inlaid particlesare of lower specific 45 metal. A gravity, then, being loosened, theymight later This art, as well as the present invention, is rise into themolten metal and so escape from also applicable not only to processesfor inlay the surface where their presence is desired. It ing thesurfaces of cast material with abrasives, iS my belief that thisformation 0f a Skin 0r lm but for the in1aying of a. cast metal surfacewith of slag impurities 0r oxides 0r colder metal sep- 5o particles ofany nature such as with other metals arately or in combination, orwhatever it may be, or corrosion resistant particles of any nature, alsois a major underlying cause that Prevents or other related arts, andwhile the discussion the securing of a good bond between the inlaid i,of the present disclosure is directed largely to particles and themetal. If the skin be slag or the production of abrasive inlaid wearingsuroxide, it will persist between the body of the 55 metal and theinlaid particles, and prevent a good bond. If it merely be colder metal,it will be more viscous and so will not flow freely into the intersticesby the inlaid particles and Iso 5 will not completely surround and imbedthem in metal. It the skin bea combination of impurities and coldermetal, the result will be the same, but more pronounced.

I have found that by so arranging my mold as to rupture this skin atfrequent and repeated intervals and so maintain conditions whereinunfilmed higher temperature limpid metal repeatedly and rapidly may beliberated and brought in contact with the inlay-particle carrying moldsurface, I

may secure a more even distribution of the inlaid material and a moreperfect bonding of the inlaid material with the metal. My methodconsists of using a mold in which obstructions of a character anddistribution designed to secure this repeated nlm rupture are placed sothat the advancing wave of metal will contact them, and of distributingthe inlay-particles in the mold with such respect to these obstructionsthat the benets of the film rupture may be best secured. For

the purposes of the present description, I will A refer to theseobstructions as dams. It is my belief that as the advancing flow ofmetal encounters'and rises over each of these dams, it is piled up tosome slight extent and this piling forces a breaking of the skin formedaround the metal and permits hotter, less viscous, and cleaner metal toflow from the interior of the advancing body of metal to surround theinlay-particles J'ust in advance of the point of rupture of the fllm.

It is my belief that a greater portion of the advantages and objects ofthis invention are attained by this action, although I also believe thatthe presence of the dams tends to break up the sweep or ilow of metaland cut down the velocity 40 of that portion of it adjacent theinlay-particle carrying mold surface, and that this also contributes aportion of the results noted.

What I have found is that in the production of a particle inlaidsurface, if the mold be formed so that it presents dams or obstructionsto the ilow of metal, if these obstructions be reasonably continuous, ifthey be placed generally transverse to the direction of ilow of metalwhen casting, if the proportions between the height of obstruction andspacing between obstructions be proper,

and if inlay-particles be placed on the mold surface between suchobstructions, then the various objects and advantages mentioned hereinmay be obtained.

In order to illustrate this invention, I now make reference to a drawingwhich is attached to and forms a part of this specification. The singleilgure of this drawing represents a diagrammatic section of a mold withmetal flowing thereinto, in

which I represents the mold, 2 represents the grains of inlaid materialon the surface thereof, and 3 represents the dams. 4 is intended torepresent the metal iiowing into the mold and 5 is intended to representthe hn or skin of oxide, or

slag-like impurities or of colder metal of which I have spoken above. Itwill be noted that the direction of flow is assumed to be from left toright and that the dams are placed in a direction transverse to that ofthe flow of metal. It will be observed that in mounting the dam 3 nextthe lefthand end, that the metal has piled up behind the dam to anextent which has enabled the hotter metal from the interior to breakthrough the skin and to ilow over the dam into the succeeding pocket andsurround the inlaid material therein with a metal which is generallyfree from this film or skin and which is considerably hotter (possibly200500 F.) than the metal which would normally have been brought incontact with this inlaid material had the film remained unbroken. Itwill also be observed that adjacent the next dam 3 the im is againforming over the surface of the advancing metal and it must again bebroken in order that the hot metal from the interior of the flow may bereleased' to come in contact with the inlaid material to the right ofthis second dam 3. It will also be observed that these dams are sopositioned as to break up and lessen the velocity of sheet flow of themetal over the surface of the mold.

The dimensions and spacing of the dams or of the dam forming grooves inthe pattern are of importance. I have found that the minimum dimensionsof groove to obtain this beneficial result are determined by thefollowing considerations. The depth of groove should preferably be notless than ik", as the beneficial results disappear quite rapidly belowthis depth. A greater depth of groove will not give increases inprotection corresponding to the increases in depth of groove; and toogreat a depth of groove, say of the nature of 1/2 gives rise to acascade action of metal on the down stream side, which may displace theinlaid material. As for width, the width of the groove in the pattern orthe width of the dam in the mold need only be enough to give the damsuflicient strength to withstand the impact of the flowing metal. I havefound for example,

that with a groove 1A," deep, a preferable width.

is about 1A?. 'I'he proper spacing of the grooves or dams is of specialimportance. This depends to some extent upon the depth of metal abovethe dam, that is upon the thickness of the nnal casting, since in thinsections, the amount of highly heated metal which may flow from theinterior of the advancing body after rupture of the film is much lessthan with thicker sections, and the exact spacing of the grooves dependstherefore upon the thickness of the casting to be made. I have found forinstance, that on castings only thick, that the spacing between groovesshould not be in excess of approximately V4", while on castings 11/2thick, or in excess of that thickness, a spacing of the grooves 11/2apart gives rise to good results. For castings of thicknesses betweenthese limits, proportional changes should be made in the spacing of ,thegrooves.

With respect to the disposition and general configuration of the dams,the following may be noted. The dams may be continuous or discontinuous,but if discontinuous should not be so short in length that the film ismerely punctured by the individual short dam instead of broken for somelittle space. The dams should be so placed on the mold surface that theyare in gendirection of iiow of the entering metal. They may well bedisposed in intersecting or interlaced groups to form a pattern in thesurface of the :final product. Heretofore, I have spoken of the dams asbeing composed of mold material, and resulting in a groove in the finalmolded surface. I am not restricted thereto, but find myself able to useandcontemplatethe use of dams in the mold, which dams are themselvescomposed of metal or other material, alike or different from the castingbody metal and from the inlay-particle material and which, when theoperation of casting is finished, will themselves appear in the form ofan inlay in the cast surface.

It is to be noted that I may place my inlayparticles in anypredetermined location, and amx them there by any of the methods hereindiscussed. For example; if I am making a stair 5 tread with abrasiveinlay, I may place large quantities of abrasive near the front edge, forwear resistance as Well as friction, and only place enough in the restof the tread for friction purposes, and may be assured that thedistribution 10 in the nal product Will be as planned.

I claim:

1. The method of manufacturing articles having particle-inlaid castmetallic surfaces which comprises the steps of providing a mold having15 a surface on which the inlay-particles are distributed, admittingmolten metal to such mold to ow over said mold surface, and while saidmetal is flowing, repeatedly interrupting the flow and rupturing thefilm formed over the advancing 20 body of metal to permit portions fromthe in terior thereof to ow forth and surround the inlay-particlesadjacent the advancing metal.

2. The method of manufacturing particle-lnlaid cast metallic surfacescomprising admitting molten metal to a mold to ow over and be formed bya surface upon which inlay particles are distributed, said mold surfacebeing additionally provided with obstructions so distributed as toprevent ow along the surface in any direction for any substantialdistance and of such. size as to cause the metal which overows theobstruction to come preponderantly from within the obstructed body offlowing metal.

3. The method of claim 2 in which the obstructions are in the form ofmolded dams from 1,/8" to 1/2" in height and spaced from 1A" to 11/2"apart.

d. The method of claim 2 in which the obstructions are molded damsdisposed in interlacing patterns upon the surface of the mold.

5. The method of claim 2 in which the ob.

structions are themselves an inlay material and upon cooling of thecasting remain in the surface thereof as an inlay, with particles ofadditional inlay distributed in other portions of the surface.

CARLISLE S. GLEZEN.

